DE102016223571A1 - Production of nonwovens including a component - Google Patents

Abstract

The present invention relates to a method of producing a nonwoven fabric (13) comprising the steps of: (a.) Providing a substrate (12), the substrate (12) being air permeable in at least a portion of its surface; (b.) providing a fiber transfer device (14) adapted to transfer fibers (11) to the substrate (12); (c.) transferring a first plurality (21) of fibers (11) to the substrate (12); (d.) applying a pressure differential to the air permeable portion of the substrate, wherein the magnitude of the pressure differential across the surface of the substrate (12) is varied.

Description

Technical area

The present invention relates to a method for producing a three-dimensional nonwoven fabric and a nonwoven fabric produced by this method.

State of the art

Nonwovens consist of fibers which are bonded together by means of chemical treatment, mechanical treatment, heat or solvent treatment. In contrast to woven or knitted fabrics, the non-woven fibers are not in the form of threads that are mechanically fixed by means of a loop or loop structure. Nonwovens are used for a wide range of products and articles including footwear, apparel and sporting goods.

The US 2006/0276095 A1 relates, for example, to a nonwoven material footwear article and a method of making the same.

The WO 2016/099687 A1 is directed to a nonwoven material, a method of making the same, and articles containing the nonwoven material.

The WO 2014/167420 A2 relates to an apparatus for producing a nonwoven product in a non-industrial environment.

The GB 1 363 675 is directed to a method of making shoes.

The EP 2 412 856 B1 relates to an apparatus for producing a three-dimensional nonwoven fabric structure.

The nonwovens in such articles are often not very rigid and durable. It is thus the technical object underlying the present invention to provide a process for producing a stable and durable nonwoven fabric in an efficient and cost effective manner.

Summary of the invention

According to a first aspect of the present invention, this object is achieved by a method for producing a nonwoven fabric comprising the following steps: (a.) Providing a substrate, wherein the substrate is permeable to air in at least part of its surface; (b.) providing a fiber transfer device adapted to transfer fibers to the substrate; (c.) transferring a first plurality of fibers to the substrate; and (d.) applying a pressure differential to the air permeable portion of the substrate, wherein the magnitude of the pressure differential across the surface of the substrate is varied.

According to the invention, the substrate is permeable to air in at least part of its surface, and the method comprises the step of applying a pressure difference to the air-permeable part. In particular, the pressure difference may be applied so that the fibers transferred to the substrate are attracted to the pressure difference. This allows a denser arrangement of the fibers to produce a denser nonwoven fabric. On the other hand, the fibers are not compacted in those areas of the surface of the substrate, which are not permeable to air, for example. It is thus possible to provide a nonwoven fabric with padded zones (non-densified fibers) and areas of increased structural strength (densified fibers).

A suction provided by a pressure difference is particularly advantageous with concave three-dimensional substrates, because otherwise the fibers tend to bridge concave portions of such a shape. When a pressure differential, and in some embodiments a higher pressure differential, is applied to the concave portions of the substrate, the fibers are drawn into the concave portions to conform to the shape of the substrate.

According to the invention, the pressure difference across the surface of the substrate can be varied. In this way, the fibers can be densified to varying degrees throughout the nonwoven fabric. In this way, the thickness of the nonwoven fabric can be varied locally. In addition, varying the pressure differential can affect the trajectories of the fibers to move the fibers to specific locations
to conduct on the substrate. In particular, the fibers may be directed to concave areas (or depressions) in which the fibers may accumulate, for example to produce a cushioning member.

By varying the air permeability of the substrate, the substrate may have different air permeable areas with different local average air permeability values. For example, some parts may be impermeable while at least one other part may be air permeable.

The air-permeable part may have a plurality of holes. This allows varying the air permeability in a relatively simple manner, for example by varying the density and / or the diameter of the holes over the surface of the substrate.

The substrate may be a three-dimensional shape. The three-dimensional shape may be a three-dimensional shape having a combination of convex and concave surface portions. The three-dimensional shape may be, for example, the last of a shoe or a shape of a bra or a torso. It can also be spherical, such as the shape of a ball bubble. The nonwoven fabric may be the part of a garment, a shoe or a sports equipment. Thus, no additional forming of the nonwoven fabric is required because it is made directly in this convenient form.

The forming of the nonwoven fabric directly on a three-dimensional shape is advantageous in the context of the present invention, because the component can also be placed on the three-dimensional shape. This reduces or eliminates wrinkling which would occur, for example, if the nonwoven web were formed on a planar substrate and bent into a three-dimensional shape. In addition, integrating the component into the nonwoven fabric while it is being formed on the three-dimensional mold is advantageous because the component can be rigid and thus can be made directly in its final three-dimensional shape, e.g. by injection molding. In such embodiments, no additional step of deforming the component from a two-dimensional shape into a three-dimensional shape is required.

The method may further comprise the steps of placing a component at least partially on the first plurality of fibers that is transferred to the substrate; and transferring a second plurality of fibers to at least a portion of the component and to at least a portion of the first plurality of fibers.

This allows the component to be integrated directly into the nonwoven, thereby improving the fit and comfort of the finished product. For example, the component may be rigid or semi-rigid to provide, for example, stiffness and / or support to the nonwoven web. It can e.g. a heel and / or toe cap are incorporated directly into a nonwoven fabric for a shoe upper. The component may also be a soft component, e.g. a foam or fleece pad. For example, it can be used in a shoe as extra padding to provide comfort and protection to the foot. A further production step of connecting the components to the nonwoven fabrics can be dispensed with, which accelerates the production process and saves manufacturing costs. In addition, the component can not detach from the nonwoven fabric because the component is integrated inside the nonwoven fabric. The finished product or article in which the nonwoven fabric is to be used is therefore much more durable. The component may also be integrated and attached to the nonwoven layer without the use of additional elements such as stitching or adhesive. It is therefore easier to produce a product of a single material with a component made of the same material as the fibers of the web. Such products can thus be recycled more easily.

The varied pressure differential may help to hold the component on the first layer (formed by the first plurality of fibers) before the second layer (formed by the second plurality of fibers) is applied.

It should be noted that according to the invention, the step of applying the pressure difference may be at least partially performed while the first plurality of fibers are being applied, and / or at least partially while the second plurality of fibers are being applied. For example, the pressure difference may be applied while the first plurality of fibers are being applied, but not while the second plurality of fibers are being applied. In another example, for example, the pressure differential may be applied while the second plurality of fibers are being applied, but not while the first plurality of fibers are being applied. In another example, the pressure differential may be applied while applying the first plurality of fibers and while applying the second plurality of fibers. In particular, in some examples, the pressure differential may be applied while placing one component on the first plurality of fibers and before applying the second plurality of fibers to hold the component in place on the substrate.

The component can have a three-dimensional shape. This includes surfaces that extend in three dimensions. Thus, complex three-dimensional nonwoven fabrics can be produced. The component may, for example, have the three-dimensional shape of a heel or toe cap or a cushioning element.

The fiber transfer device may be a meltblown head. In a melt-blown process, molten filaments exit a spinneret, are drawn from a primary air stream, and are broken up into staple fibers by eddy currents. A secondary air stream transfers the fibers to the substrate. Meltblowing is a very efficient process for the production of nonwovens. The fleece is a meltblown web.

The surface area of the component may be smaller than the surface area of the nonwoven fabric, and the component may be placed so as to be embedded in the nonwoven fabric. The component is thus completely enclosed by the fibers of the nonwoven and is held in position in all directions. In addition, it is protected from the fibers of the nonwoven fabric from mechanical or chemical stresses (including moisture) from the outside. This may be particularly advantageous if the component is an electronic component.

The component may have at least one extension adapted to be enclosed by fibers. The extension ensures that the component is fixed relative to the nonwoven fabric and also prevents inadvertent slippage of the component inside the nonwoven fabric.

The component may have at least one opening such that fibers of the second plurality of fibers applied in the opening are transferred to the first plurality of fibers. The component may, for example, have a loop-like structure. In this way, the component is held firmly in position at least by the fibers in the opening.

The component may have a shape such that it is held in place by fibers. In particular, the component may have a shape such that it is held in position by fibers of the first plurality of fibers and / or the second plurality of fibers. This can be achieved for example by the extension and / or the opening as described above.

The component may have a textured surface. In this way, the fibers that come in contact with the surface of the component adhere better to the component.

At least one surface of the component may comprise a fusible layer. The fusible layer may face the first plurality of fibers or the second plurality of fibers. Thus, for example, when a meltblown process is used to transfer the fibers to the substrate, the fibers may melt or soften the fusible layer as they reach the surface of the component with residual heat. This provides a strong connection between the component and the fibers. Alternatively or additionally, at least one surface of the component may have an adhesive layer.

The melting temperature of the fusible layer may be below the temperature of the fibers as they impinge on the component. In this way, the heat of the fibers can be used to melt or soften the fusible layer. Further, additional heating of the fusible layer can therefore be dispensed with.

In general, the temperature of the transferred fibers is such that the transferred fibers are sufficiently soft / melted that they adhere to the deposited fibers as they impact the deposited fibers.

The component can have a varying thickness. The component may be, for example, a piece of foam or non-woven, an air bladder or a bag containing a fluid, such as e.g. Air surrounds. In this way, a cushioning or damping effect can be achieved.

The three-dimensional shape may be a last for a shoe or a part thereof. The method can thus be advantageously used to produce a shoe upper or a part thereof. The step of forming a two-dimensional nonwoven fabric into the shape of a shoe upper can be dispensed with since the nonwoven fabric is shaped in a three-dimensional shape due to the three-dimensional contour of the last. Such a technique can provide a shoe top without seam, allowing it to be produced faster and more comfortable.

The three-dimensional shape may be spherical, and the nonwoven fabric may be suitable for use as a layer for a ball or as a part thereof. Such a layer or part may for example be a bubble, a carcass, a padding, a panel, an outer surface, etc. Such a layer or part of a ball can thus be produced in a single operation and directly in a three-dimensional form. The usual difficulties of forming a two-dimensional ball component into a three-dimensional ball component, such as e.g. the assembly of several panels are avoided.

The three-dimensional shape may be spherical, and the nonwoven fabric may be suitable to be used as the outer surface of a ball. In this case, the method may further comprise the step of heating and compressing the nonwoven fabric. In addition, the nonwoven fabric can be textured. Such a texture can improve the aerodynamics and adhesive properties of the finished ball. A spray PU may be applied to the nonwoven web to provide an outer layer with more abrasion resistance, less water intake, with colors, etc. to form.

The advantage of making a ball or parts thereof with a nonwoven technique as described herein is that the same properties can be achieved in any direction of the fabric. Also for the production of a ball, the substrate may have an opening which becomes the valve opening (where no fleece can be applied where the receptacle of the substrate connects to the substrate). The substrate may in particular be a ball bubble. Another option is to roll a spherical substrate in many different directions under the fiber transfer device so that each side is sprayed with fleece.

The method may further comprise the step of feeding the fiber transfer device with a thermoplastic polyurethane (TPU) material. These materials are well suited for a meltblown process. TPU has a wide processing window, which makes it easier to work with. TPU also has excellent mechanical properties, e.g. high elasticity. TPU has good self-adhesion due to low crystallization temperature, which facilitates the formation of multiple layers. TPU is often used in the manufacture of shoes, e.g. for plates in football boots, soles, heel caps, etc., which makes it easier to recycle the entire shoe. This material is also suitable for the manufacture of components to be integrated into the fleece so that a product can be made from a single material. Since these materials can also be recycled, the recycling of such products is simplified. The polypropylene material may be, for example, a medium melt viscosity polypropylene suitable for processing into a wide range of thread sizes and fabric structures.

The meltblowing head may have a plurality of nozzles. In this way, the rate of blown fibers per unit time can be increased and the surface area occupied by meltblown fibers increased, and the overall processing time can be reduced.

The method may further comprise the steps of feeding at least a first nozzle with a first material; and feeding at least one second nozzle with a second material, wherein the first material and the second material are different. By feeding nozzles of different materials, a nonwoven fabric may be formed with a blend of fibers of different materials having possibly different properties (e.g., elasticity, color, diameter, etc.). Depending on the relative movement between the meltblowing die and the substrate, the two types of material may be mixed or each of which may form part of the nonwoven fabric.

The method may further comprise the steps of transmitting a first material for a first period of time; and transmitting a second material for a second period of time, wherein the first material and the second material are different. In this way, a first layer of a first material can be produced and then a second layer with a second material. Due to the different materials of the fibers, the layers may have different properties, but they may be bonded together without gluing, sewing or welding.

The method may further comprise the steps of transferring a first material to a first part of the mold; and transferring a second material to a second part of the mold, wherein the first material and the second material are different. The finished nonwoven fabric can thus be equipped with different materials in different parts. For example, a shoe upper may have a stiffer material in the toe and heel regions and a more elastic material in the other parts of the shoe upper. Thanks to the method according to the invention, the two parts can connect to each other without additional connecting means such as gluing, sewing or welding. In particular, an integral, one-part nonwoven fabric can be achieved in this way, and seams can be avoided.

The second material can be transferred to the first material with only a short delay so that the first material is still soft when the second material is applied to ensure a good bond between the two materials. Alternatively, or in combination, the temperature of the second material may be adjusted high enough upon application to soften or melt the first material when the two materials contact each other. The temperature of the second material upon impact with the first material may be about 60-70 ° C.

The method may further comprise the step of feeding the at least one nozzle of the meltblowing head with a first material and a second material in a side-by-side configuration. In this way fibers can be made of several materials.

The first material may be a first TPU material and the second material may be a second TPU material, wherein the first TPU material has a different class than the second TPU material. In this way, a very good connection of the fibers can be achieved. At the same time, the hardness and the mechanical properties can be varied.

In general, the material used to form the fibers can be chosen to stretch more or less once set (i.e., cooled). The extensibility can thus be selected based on the desired application of the nonwoven fabric. In addition, the invention enables the production of thin flexible layers in one piece, even with complex shapes such as a last, in particular a last including convex shapes. In fact, even though the strip is rigid and is inside the nonwoven fabric, it can be easily removed from the three-dimensional nonwoven fabric even if the strip has a convex shape or a plurality of convex shapes because the nonwoven fabric is stretchable so as to remove the last allow, for example through an ankle opening of the shoe upper.

The method may further comprise the step of transferring at least a third plurality of fibers to the substrate after the first plurality of fibers or after the second plurality of fibers, wherein the material of the third plurality of fibers is comprised of the material of the first plurality of fibers and / or the second plurality of fibers. In this way, a multilayer nonwoven fabric can be produced without having to join the layers in a separate step. The third plurality of fibers may be transferred in the same direction as the first and / or second plurality of fibers or in another direction.

The method may further include the step of moving the fiber transfer device relative to the substrate. In this way, the fibers can be applied to the substrate at different locations and / or at different distances and / or from different directions. This allows the production of a rather complex nonwoven fabric, e.g. with varying thickness. If the substrate has a three-dimensional shape, it is possible to distribute the fibers substantially uniformly by appropriately moving the fiber transfer device and the substrate. For example, it is possible to impinge the fibers on each part of the substrate at a right angle on the three-dimensional shape, which would not be possible with a static arrangement of the three-dimensional shape and the fiber transmission device. "Movement" in the context of the present invention is to be understood as translation, rotation or a combination of both. The relative movement may be, for example, a linear translation or a combination of a linear translation and small rotations. In particular, the rotations are preferably at a higher frequency when rotations and translations are used.

The invention also includes a method of producing a nonwoven fabric comprising a step of laying a greater proportion of fibers in a predetermined direction than in other directions. The relative movement of the fiber transfer device relative to the substrate may be used to lay a greater proportion of fibers in a predetermined direction than in other directions to produce an anisotropic nonwoven web. This step may be combined or not combined with other steps of inventive methods. This can in particular also be achieved without integrating a component as proposed by the present invention. In general, the higher the relative velocity between the substrate and the fiber transfer device, the higher the fraction of oriented fibers.

The substrate can be placed on a robotic arm. In this way, a better distribution of the fibers can be provided. For example, the robotic arm can be moved to provide a uniform distribution of fibers. In another example, the robotic arm may follow a complex pattern, e.g. a combination of translations in different directions and rotations. It is advantageous to displace the substrate rather than the fiber transfer device since it is usually easier to displace the substrate in three dimensions than the fiber transfer device since it requires at least one feed of fiber material. A robotic arm is also advantageous in the case of some complex three-dimensional shapes such as e.g. of a shoe last, since it allows the three-dimensional shape to be rotated 360 degrees. The robotic arm also permits controlling the distance between a surface of the substrate and the fiber transfer device to impart certain properties to each region of the nonwoven fabric. In fact, the distance between the fiber transfer device and the surface can affect the structure and / or thickness of the nonwoven layer: the smaller the distance, the denser and / or thicker the nonwoven layer. The robot arm, for example, allows a constant distance to be maintained between a surface of the substrate and the fiber transfer device, even with complex shapes such as a ledge, so that the properties of the nonwoven layer are uniform throughout the shape.

Alternatively or additionally, the fiber transmission device can be placed on a robot arm. However, in some advantageous embodiments, the fiber transfer device is stationary. In fact, a fixed fiber transmission device is easier to maintain and less expensive than a movable fiber transmission device.

The method may further comprise the step of using an air stream to control the direction of fiber transmission. In this way, the application of the fibers can be controlled without having to move the fiber transfer device of the substrate. For example, with a meltblowing head, a tertiary airflow may be used to control the direction of the trajectories of the fibers.

The method may further comprise the step of controlling the distance between the fiber transfer device and the substrate and / or controlling the rate of relative movement between the fiber transfer device and the substrate. In this way, the distribution of the fibers over the three-dimensional shape can be controlled. Slower relative movement of the substrate and the fiber transfer device results in thicker and, in some embodiments, denser filing of fibers and vice versa.

The fiber diameter can be varied during the transfer of the fibers. The nonwoven fabric can thus be equipped with areas with different fiber diameter. The properties (such as density, breathability, etc.) of the nonwoven fabric can thus be varied locally.

Varying the fiber diameter may involve the use of at least two different spinneret holes of different diameter. In this way, the fiber diameter can be varied over a wide range of diameters. Alternatively or additionally, varying the fiber diameter may include varying the airflow. Alternatively or additionally, a first portion of fibers is transferred from a first meltblowing head, and a second plurality of fibers is transferred from a second meltblown die, wherein at least one nozzle of the first meltblown head has a smaller diameter than at least one nozzle of the second meltblown header. The fiber diameter influences the feel and mechanical properties of the nonwoven fabric. For example, the nonwoven fabric may have a stiff lower portion with thicker fibers and a more pliable upper layer with finer fibers to provide better feel.

The spacing and / or velocity may be varied during the blowing of the fibers onto the substrate. In this way, the nonwoven fabric can be given a different thickness in different areas. The nonwoven may e.g. be thicker in a first area than in a second area.

In the case of a three-dimensional shape, the shape may be concave, and the method may further include the step of transferring the fibers to an inner surface of the three-dimensional shape. The three-dimensional shape may include a shoe cavity such as e.g. a shoe mold (e.g., the negative of a last) or an upper layer made by the method of the present invention or other existing method (such as knitting, weaving, molding, etc.). In this case, an inner layer of a shoe upper can be produced from a nonwoven fabric, whereby a particularly good fit can be provided. The inner layer forms e.g. an inner sock and / or padding.

A first layer and the nonwoven layer can each cause a different function. For example, the first layer may provide an impregnation or support the foot in certain areas, while the nonwoven layer may be an inner sock providing comfort. Such a feature also enables the production of a shoe upper from a single material (e.g., TPU) by combining a layer or component of a particular material and a nonwoven component or layer of the same material. The recycling of the shoe is thereby facilitated.

In general, the process of the present invention allows for the production of a three-dimensional sock made of nonwoven fabric, either by blowing fibers onto a last or into a shoe cavity, which therefore also has a lower part, i.e. a lower part. a part under the foot. Such a technique may also enable the formation of a nonwoven fabric on the three-dimensional shape only in some areas to provide cushioning, in some embodiments a padding of the same material as the rest of the shoe. The formation of a nonwoven fabric in layers can also enable the production of an isotropic layer or an anisotropic layer. An anisotropic layer can be made by laying a higher proportion of fibers in a predetermined direction than in other directions. This can be done, for example, by moving the fiber transfer device relative to the substrate in the predetermined direction.

The method may further comprise the steps of covering the substrate at least partially with a base layer; and transferring at least a portion of the first plurality of fibers and / or the second plurality of fibers to the base layer. The nonwoven fabric can thus be connected directly to the base layer without a further bonding step. For example, a nonwoven fabric for a shoe upper may be formed directly on a water repellent membrane. The base layer can be, for example, a textile such as a woven or knitted fabric. Alternatively, the base layer may be, for example, a leather or a nonwoven.

The method may further comprise the step of transferring the first plurality of fibers and / or the second plurality of fibers to a first region of the substrate but not to a second region. This allows the design of a nonwoven fabric of the desired dimensions without the need for cutting. For example, a nonwoven fabric for a shoe upper may be configured by transferring fibers only to an upper surface of a last, but not to a lower surface. In another example, if the nonwoven fabric is for a back part of a shoe upper, fibers may be transferred to a back part of a last, but not to a front part. Thanks to the invention, it is possible to integrate a heel counter directly into the heel part of the shoe upper.

Alternatively or additionally, the method may include the step of varying the duration of applying fibers. For example, fibers may first be applied only in a first area, and then only in a second area. In another example, fibers are first applied almost everywhere to the substrate and / or the component, and then only to a second area (or vice versa).

The holes may also be provided by the loops of a net or the pores of a porous material. The substrate may for example be a porous strip. A substrate with holes can be made by additive manufacturing such as 3D printing.

The magnitude of the pressure differential may be varied across the surface of the substrate to locally vary the thickness of the nonwoven. Thus, a more complex nonwoven fabric of varying thickness can be produced. The nonwoven fabric for a shoe upper may e.g. be thicker in the heel area to provide some padding in this area.

The three-dimensional shape can be textured. In this way, the nonwoven fabric can be easily provided with a textured surface. For example, a nonwoven fabric for a shoe upper for a soccer shoe may be provided with a texture to increase the adhesion with a football.

The texture applied to the nonwoven fabric may be controlled by selecting the structure and / or the porosity of the surface of the substrate. If a pressure difference is applied as described above, the texture can also be controlled by the magnitude of the pressure difference.

The method may further include the step of laying a removable membrane over the nonwoven fabric while in the three-dimensional shape. This is particularly advantageous in connection with the application of a pressure differential across the substrate as it allows additional densification of the nonwoven fabric.

The method may further include the step of applying a pressure differential after the removable membrane has been placed. In this way, the nonwoven fabric can be consolidated. If a textured membrane is used, the nonwoven fabric may be provided with surface texturing.

The membrane can be textured. Thus, the nonwoven fabric may also be provided with a textured upper surface (i.e., the surface facing away from the substrate). In conjunction with a textured substrate it is possible to texture the nonwoven fabric on both sides.

The method may further comprise the step of applying pressure and / or heat to the nonwoven web. In particular, the method may include the step of applying pressure and / or heat to the nonwoven fabric while it is in the three-dimensional shape. For example, this step may be performed while placing the membrane over the nonwoven fabric. In this way, the surface of the nonwoven fabric can be consolidated and / or finished. In particular, it can be textured and / or condensed. The application of heat will also improve the abrasion resistance and other mechanical properties such as tensile strength and tear resistance. It is possible to apply pressure and / or heat only locally, i. only to certain areas of the nonwoven fabric.

In some embodiments, pressure and / or heat may be applied locally to the web to locally alter the properties of the web. As a result, for example, some reinforcements can be generated locally.

On a two-dimensional nonwoven fabric at least heat and / or pressure can be applied by calendering.

In general, curing the outer surface of the nonwoven fabric (by applying heat and / or pressure) may allow the production of a layer that is stronger with less water absorption, better abrasion resistance, etc. In addition, a design on the outside may be imprinted by: Heat and / or pressure is applied.

Another aspect of the present invention relates to a nonwoven fabric prepared according to a method as described above.

Another aspect of the present invention is directed to a method of manufacturing a shoe upper. The method comprises the step of producing a first nonwoven fabric according to a method as described above, wherein the first nonwoven fabric is a part of the shoe upper.

The method of making a shoe upper may further comprise the steps of making a second nonwoven fabric according to a method as described above, wherein the second nonwoven fabric is part of a shoe upper; and bonding the first nonwoven fabric and the second nonwoven fabric. For example, different parts of a shoe upper may be made in the form of components of the shoe upper with three-dimensional shape and then joined together, for example by applying heat (eg welding), or applying adhesive etc. Such a component may also be applied to layers or components of different types be added, such as components made of different materials and / or components made by different manufacturing techniques (e.g., knitting or weaving).

Another aspect of the present invention relates to a shoe upper made according to a method as described above.

Yet another aspect of the present invention relates to a process for producing a nonwoven fabric comprising the steps of: (a.) Providing a substrate; (b.) providing a meltblowing head adapted to transfer fibers to the substrate; (c.) feeding at least a first nozzle of the meltblowing head with a first material; (d.) feeding at least a second nozzle of the meltblown head with a second material, wherein the first material and the second material are different; and (e.) transferring the first material and the second material to the substrate. By feeding nozzles with different materials, a nonwoven fabric may be formed with a mixture of fibers of different materials having possibly different properties (e.g., elasticity, color, diameter, etc.). Depending on the relative movement between the meltblowing die and the substrate, the two types of material may be mixed or each of which may form part of the nonwoven layer.

The method may further comprise the steps of transmitting the first material for a first period of time; and transferring the second material for a second period of time, wherein the first material and the second material are different. In this way, a first layer of a first material can be produced and then a second layer with a second material. Due to the different materials of the fibers, the layers may have different properties, but they may be bonded together without gluing, sewing or welding.

The method may further comprise the steps of transferring the first material to a first part of the mold; and transferring the second material to a second part of the mold, wherein the first material and the second material are different. The finished nonwoven fabric can thus be equipped with different materials in different parts. For example, a shoe upper may have a stiffer material in the toe and heel regions and a more elastic material in the other parts of the shoe upper. Thanks to the method according to the invention, the two parts can connect to each other without additional connecting means such as gluing, sewing or welding. In particular, an integral, one-part nonwoven fabric can be achieved in this way, and seams can be avoided.

The second material can be transferred to the first material with only a short delay so that the first material is still soft when the second material is applied to ensure a good bond between the two materials. Alternatively, or in combination, the temperature of the second material may be adjusted high enough upon application to soften or melt the first material when the two materials contact each other. The temperature of the second material upon impact with the first material may be about 60-70 ° C.

The first material may be a first TPU material and the second material may be a second TPU material, wherein the first TPU material has a different class than the second TPU material. In this way, a very good connection of the Fibers are achieved. At the same time, the hardness and the mechanical properties can be varied.

Yet another aspect of the present invention relates to a process for producing a nonwoven fabric comprising the steps of: (a.) Providing a substrate; (b.) providing a meltblowing head adapted to transfer fibers to the substrate; (c.) feeding at least one nozzle of the meltblowing head with a first material and a second material in a side-by-side configuration; and (d.) transferring the first material and the second material to the substrate. In this way fibers can be made of several materials.

The first material may be a first TPU material and the second material may be a second TPU material, wherein the first TPU material has a different class than the second TPU material. In this way, a very good connection of the fibers can be achieved. At the same time, the hardness and the mechanical properties can be varied.

Yet another aspect of the present invention relates to a process for producing a nonwoven fabric comprising the steps of: (a.) Providing a substrate; (b.) providing a fiber transfer device adapted to transfer fibers to the substrate; (c.) transferring fibers to the substrate by the fiber transfer device; and (d.) controlling the distance between the fiber transfer device and the substrate and / or controlling the rate of relative movement between the fiber transfer device and the substrate. In this way, the distribution of the fibers over the three-dimensional shape can be controlled. Slower relative movement of the substrate and the fiber transfer device results in thicker and, in some embodiments, denser filing of fibers and vice versa.

Controlling the distance between the fiber transfer device and the substrate and / or controlling the speed of relative movement between the fiber transfer device and the substrate may be accomplished by attaching the fiber transfer device and / or the substrate to a robotic device such as a robot. a robot arm whose path is predetermined and / or controlled. The relative movements of the fiber transmission device and the substrate can be controlled in particular by a computer program.

The fiber diameter can be varied during the transfer of the fibers. The nonwoven fabric can thus be equipped with areas with different fiber diameter. The properties (such as density, breathability, etc.) of the nonwoven fabric can thus be varied locally.

Varying the fiber diameter may involve the use of at least two different spinneret holes of different diameter. In this way, the fiber diameter can be varied over a wide range of diameters. Alternatively or additionally, varying the fiber diameter may include varying the airflow. Alternatively or additionally, a first portion of fibers is transferred from a first fiber transfer device and a second plurality of fibers are transferred from a second fiber transfer device, wherein the first portion of fibers has a smaller average diameter than the second portion of fibers. The fiber diameter influences the feel and mechanical properties of the nonwoven fabric. For example, the nonwoven fabric may have a stiff lower portion with thicker fibers and a more pliable upper layer with finer fibers to provide better feel.

In the case of a three-dimensional shape, the shape may be concave, and the method may further include the step of transferring the fibers to an inner surface of the three-dimensional shape. The three-dimensional shape may include a shoe cavity such as e.g. a shoe mold (e.g., the negative of a last) or an upper layer made by the method of the present invention or other existing method (such as knitting, weaving, molding, etc.). In this case, an inner layer of a shoe upper can be produced from a nonwoven fabric, whereby a particularly good fit can be provided. A first layer and the nonwoven layer can each cause a different function. For example, the first layer may provide an impregnation or support the foot in certain areas, while the nonwoven layer may be an inner sock providing comfort. Such a feature also enables the production of a shoe upper from a single material (e.g., TPU) by combining a layer or component of a particular material and a nonwoven component or layer of the same material. The recycling of the shoe is thereby facilitated.

According to all aspects of the present invention described in this document, the nonwoven fabric may be used as a first layer of a garment soundproofing structure. The sound insulation structure may comprise at least a first layer comprising a sound absorbing material, and at least one second layer adapted either to reflect sound, to scatter sound or both. In particular, the size and density of the nonwoven fabric can be selected to achieve high sound absorption in a desired frequency range.

The second layer can be produced by a post-processing of a side of the first layer of non-woven, for example by applying heat and / or pressure. The second layer can also be made by applying heat and / or pressure to the nonwoven fabric and then bonded to the first layer.

The substrate on which the nonwoven fabric is formed may be a three-dimensional shape as described above. The nonwoven layer can thereby be formed directly in a three-dimensional shape of the finished product. Thus, no additional forming of the nonwoven fabric is required because it is made directly in this convenient form. The three-dimensional shape may be, for example, the shape of a head or a hood, a bag, etc.

The substrate may have a texture. The nonwoven layer thereby assumes a negative texture on the side which contacts the substrate. Such a texture can improve comfort and / or sound dispersion.

The substrate may have a plurality of holes in at least a portion of its surface, and the method may further comprise the step of applying a pressure differential to the plurality of holes such that the fibers transferred to the substrate are attracted to the pressure differential. This allows a denser arrangement of the fibers to produce a denser nonwoven fabric. In some embodiments, it may also allow the creation of a texture on the surface to enhance its sonic dispersion, sound absorption and / or comfort: in particular with a substrate having the shape of a wide array in which the fibers penetrate into the holes of the assembly be pulled to form padded bumps on the inner surface of the nonwoven fabric.

list of figures

• 1 zeigt schematisch ein beispielhaftes Schmelzblasverfahren, das im Zusammenhang mit der vorliegenden Erfindung verwendet werden kann;
• die 2A und 2B zeigen eine beispielhafte Ausführungsform eines Teils eines Vliesstoffs, der gemäß einem Verfahren der vorliegenden Erfindung hergestellt wurde;
• die 3A und 3B zeigen eine beispielhafte Ausführungsform eines Vliesstoffs, der gemäß einem Verfahren der vorliegenden Erfindung hergestellt wurde;
• die 4A-C zeigen ein Beispiel des Variierens der Anordnung der Löcher auf einem Substrat; und
• die 5A und 5B zeigen eine Ausführungsform einer Abwandlung des Gedankens der vorliegenden Erfindung.

Aspects of the present invention will be explained in more detail with reference to the corresponding figures. These figures show:

• 1 Fig. 12 schematically shows an exemplary meltblown process which may be used in the context of the present invention;
• the 2A and 2 B show an exemplary embodiment of a portion of a nonwoven fabric made in accordance with a method of the present invention;
• the 3A and 3B show an exemplary embodiment of a nonwoven fabric made in accordance with a method of the present invention;
• the 4A-C show an example of varying the arrangement of the holes on a substrate; and
• the 5A and 5B show an embodiment of a modification of the idea of the present invention.

Detailed description of preferred embodiments

Hereinafter, embodiments and modifications of the present invention will be described in more detail.

1 illustrates an example of how fibers 11 on a substrate 12 can be transferred to a nonwoven fabric 13 to shape. The schematic in the 1 The process shown is a meltblown process. In general, however, any technique can be used in the context of the present invention with the fibers on the substrate 12 can be transmitted.

An example of such an alternative technique is the use of electrostatic forces, ie, an electric field, which exists between a fiber transmission device such as that shown in the US Pat 1 with the reference number 14 is shown, and the substrate 12 is created.

In the in the 1 shown meltblowing process is a resin 15 in a spinneret 16 fed. An example of an easily processed resin for making a variety of different nonwoven structures is a polypropylene homopolymer. In general, any material suitable for use in a meltblowing process may be used in the context of the present invention. An example of such a material is thermoplastic polyurethane (TPU).

The resin 15 gets in the spinneret 16 heated to a temperature above its melting temperature. The spinneret 16 includes an opening with a small diameter, such as between 15 and 30 microns, creating a nozzle 17 is formed. The molten resin 15 is from a primary airflow 18 in the form of threads from the nozzle 17 drawn. Eddy currents break the threads into fibers 11 a certain length, referred to as staple fibers. A secondary airflow 19 transfers the fibers 11 on the substrate 12 , Of the Air flow thus causes the fibers to fall like a reverse tornado, revolving with the (rotating) eddy currents in the air, increasing the diameter of the circles toward the target. In this way, the nonwoven fabric 13 formed as a random array of fibers.

The fibers 11 which are produced in this way have a diameter of 1 .mu.m to 100 .mu.m, preferably between 5 .mu.m and 50 .mu.m, most preferably about 10 .mu.m and 30 .mu.m.

It should be noted that the fiber transmission device 14 a variety of such nozzles 17 may have to increase the production rate of fibers 11 to increase. It is also possible to have a first part of a plurality of nozzles 17 to feed with a first material, and a second part of nozzles 17 with a second material, wherein the first material and the second material are different. For this purpose, different resins can be used 15 be used. In this way, different types of fibers can be applied to the substrate 12 be transmitted. These fibers may mix when transferred or may be at different locations on the substrate 12 impact areas of different materials on the substrate 12 be formed.

Around areas of the nonwoven fabric 13 With different materials, it is possible to form fibers first 11 a first material to transfer to the substrate, the substrate 12 relative to the fiber transfer device, as described in more detail below, and then fibers 11 a second, different material to be applied to the substrate. This can be achieved by the resin 15 is exchanged or different nozzles 17 that with different resins 15 be used.

It is also possible to use a nozzle, such as the nozzle 17 feed with two different materials in a side-by-side configuration or as a blend to make fibers from two components. For this purpose, the fiber transmission device 14 two containers for two different resins 15 exhibit.

In the example of 1 is the substrate 12 shown with a hemispherical three-dimensional shape. In general, in the context of the present invention, the substrate may have any three-dimensional shape and have convex and / or concave surfaces. Advantageously, the three-dimensional shape of the substrate 12 adapted to the shape of the finished nonwoven fabric as used in an article. The hemispherical shape in the 1 For example, results in a hemispherical nonwoven fabric 13 , Such a hemispherical nonwoven fabric 13 For example, it can be used as a bubble, carcass or padding for a ball or part of it.

While that in the 1 shown substrate 12 convex, it may also have a concave shape, eg a hollow hemisphere. In this case, the fibers can 11 transferred to an inner surface of the hollow hemisphere. In another example, the substrate may be 12 to act a last. Accordingly, the nonwoven fabric can 13 formed on the last, having the shape of a shoe upper, a shoe sole or a part thereof. It should be noted that in the context of the present invention, the substrate 12 may also have a two-dimensional shape, ie it may be planar.

As by the arrows 110 displayed, the substrate may be 12 relative to the fiber transmission device 14 to be moved. This can be done by either the substrate 12 moved and the fiber transfer device 14 held in position, or vice versa. It is also possible to move both, the substrate 12 and the fiber transmission device 14 , As by the arrows 110 displayed, the substrate becomes 12 along a linear trajectory under the fiber transmission device 14 emotional. The fibers are thus first on the edge region of the substrate 12 transferred to the right side of the hemisphere, then to the middle of the hemisphere and finally to the border area on the left side of the hemisphere. When the direction of fiber transmission during the movement of the substrate 12 is kept constant, more fibers are deposited on the upper part of the hemisphere than on the sides of the hemisphere. Accordingly, the resulting nonwoven fabric becomes 13 be thicker at the top.

The substrate 12 can be more complex movements like the arrows 111 displayed. The substrate can be rotated, for example, in the vertical direction and / or in the horizontal direction. In the context of the present invention, "movement" is understood to include translation (s), rotation (s), or a combination of translation (s) and rotation (s). Rotation can be performed in any direction in space, and motion can take place along any trajectory in space.

Complex movements can be achieved by attaching the substrate 12 achieved on a robot arm (not shown in the figures). For example, the robotic arm can be moved to provide a uniform distribution of fibers 11 provide. In another example, the robotic arm may follow a complex pattern, eg one Combination of translations in different directions and rotations about one or more axes. A robotic arm is very advantageous in the case of some special three-dimensional shapes, such as a shoe last, since it allows the three-dimensional shape to be rotated 360 degrees. The robot arm also allows control of the distance 112 between a surface of the substrate 12 and the fiber transmission device 14 to any area of the nonwoven fabric 13 to give certain characteristics. In fact, the distance can be 112 between the fiber transmission device 14 and the surface some properties such as the structure and / or thickness of the nonwoven layer 13 influence. For example, the robotic arm allows for a constant distance between a surface of the substrate 12 and the fiber transmission device 14 is maintained so that the properties of the nonwoven layer 13 are uniform across the entire shape, even in complex shapes such as a last. Alternatively or additionally, the speed of movement of the robotic arm may be controlled and varied while the fibers 11 on the substrate 12 be transmitted.

Alternatively or additionally, the meltblowing head can be placed on a robot arm. In this case, the same considerations apply as above.

Instead of the fibers 11 directly on the substrate 12 It is also possible to apply a primer layer (not shown in the figures) on the substrate 12 to place and transfer the fibers to the base layer. The fibers 11 can connect with the base layer. Such a base layer can be, for example, a nonwoven, a woven or knitted fabric. The material of the base layer may be the same as the material of the fibers 11 to the connection of the fibers 11 to facilitate with the base layer.

It is also possible to use the fibers 11 not on the entire substrate 12 apply. A nonwoven fabric 13 For example, a shoe upper may be formed by transferring fibers only to an upper surface of a last, but not to a lower surface. In another example, if the nonwoven fabric is for a back part of a shoe upper, fibers may be used 11 be transferred to a rear part of a last, but not to a front part. Partial application of fibers 11 on the substrate 12 can be achieved, for example, by the substrate 12 or the fiber transmission device 14 or both are mounted on a robot arm as described above.

As by the arrows 113 in the 1 is displayed, a pressure difference is applied to the substrate 12 created. In general, the substrate is 12 permeable to air in at least part of its surface. For this purpose, the substrate 12 in the exemplary embodiment of the 1 a plurality of holes, three of which are exemplified by the reference numeral 114 in the 1 Marked are. The pressure difference causes the fibers 11 pointing to the three-dimensional shape 12 be blown, are attracted by the pressure difference. The fibers 11 are thus compressed, thus a denser nonwoven fabric 13 is achieved. The pressure difference may be generated by a vacuum source, a pump or similar device connected to the substrate 12 is connected, allowing a flow of air through the holes 114 is generated, as by the arrows 113 displayed. In this way, a suction is created.

According to the invention, the magnitude of the pressure difference across the surface of the substrate 12 be varied. Varying the magnitude of the pressure differential across the surface of the substrate 12 can be a local variation of properties such as the thickness of the nonwoven fabric 13 allow. The nonwoven fabric 13 for a shoe upper may be thicker, for example, in the area of the heel to provide some padding in this area. Varying the pressure difference may be achieved by varying the size and / or shape and / or density of the holes 114 over the surface of the substrate 12 be varied. The substrate may have some areas that are free of holes and other areas with holes 114 , In particular, some areas may have arrangements of holes.

An example of varying the arrangement of the holes on a substrate 12 is in the 4A . 4B and 4C shown. These figures show a substrate 12 in the form of a last. The last 12 has different zones with holes, some of which are exemplified by the reference numeral 114 Marked are. A first zone 41 is on a lateral instep part of the last 12 arranged. A second zone 42 is on a medial instep part of the last 12 arranged. A third zone 43 is on a middle instep part of the last 12 arranged. A fourth zone 44 is on a heel part of the last 12 arranged. A fifth zone 45 is on the waistband part of the last 12 arranged. A sixth zone 46 is on the lower medial midfoot area of the groin 12 arranged. A seventh zone 47 is on a lower medial side of a forefoot part of the last 12 arranged. By applying a pressure difference across the holes in the different zones 41 to 45 The effect of the fibers is the shape of the last 12 to adjust. Especially in the zone 46 The fibers adapt to the concave shape of the last 12 instead of bridging this concave zone. Incidentally, where the holes in depressions as in the zones 41 . 42 . 43 . 44 placed, the thickness of the nonwoven fabric compared to the areas of the last 12 having no holes can be increased to form some padded zones.

In other embodiments, the holes 114 arranged in zones, and different vacuum sources or pumps of different thickness are connected to the different zones. It is of course also possible that the substrate 12 holes only in a certain area 114 but not in another area, as in relation to the 4A-C described. In the embodiment of the 4A-C For example, the upper forefoot area has no holes so it is not permeable to air.

The holes 114 can also be in concave parts 41 . 42 . 43 . 44 (or depressions) of the substrate 12 to be placed. The placement of holes in concave portions of the substrate may allow to ensure that the fibers are pulled into this concave portion and do not bridge the concave portion. The placement of holes in the concave portions of the substrate thereby allows the creation of some padded zones. As with the examples of 4A-C It was seen on a shoe last 12 such concave parts in the heel area 44 and in the tongue area 43 created to provide a cushioning in these areas. On the other hand, holes were made in the concave parts of the lower metatarsus 46 placed to ensure that the shape of the nonwoven layer of the shape of the last 12 adapts. There were also holes in the lower forefoot area 47 placed to ensure that the fibers are the shape of the last 12 adjust along a line of small interior angle.

The substrate may have holes along lines that are the edge of the finished product such as the fret zone 45 in the example of 4A-C correspond. In fact, this allows the production of a denser configuration of the nonwoven material along these lines, providing a cleaner edge on the finished product after the nonwoven fabric has been cut along such a line.

Incidentally, the size and / or shape and / or density of the holes in the substrate may be selected to impart a texture to the nonwoven fabric. Such a texture can be used to provide comfort to the user or, for example, tactile feedback. In addition, in a method according to the invention, the nonwoven fabric can be turned to the left after it has been applied to the substrate so that the inside, which was in contact with the substrate during the application of the fibers, becomes the outside of the nonwoven fabric. This can be used to achieve some aesthetic effects or, for example, to improve adhesion. In particular, the texture of the substrate may be applied as a negative texture to the outer surface of the finished product, e.g. a shoe last, be transferred.

The substrate can be produced by additive manufacturing. This may allow the production of complex shapes of the substrate. Such a technique may also allow for the creation of very small diameter holes, e.g. less than 1 mm, in particular less than 0.5 mm, e.g. between 0.1 mm and 0.5 mm.

To the nonwoven fabric 13 With a textured surface, it is possible to have a substrate 12 to use with surface texture (not in the 1 shown). The texture of the substrate 12 is as a negative on the nonwoven fabric 13 transfer. This effect can be enhanced by using a pressure difference as explained above.

The effect of the pressure difference to densify the fibers can be enhanced by placing a removable membrane (not in the 1 shown) over the nonwoven fabric 13 while he is on the three-dimensional shape 12 located. If the membrane is impermeable or at least partially impermeable to air or gas, the membrane becomes nonwoven 13 sucked and compacts the fibers 11 , In addition, heat may be applied to the membrane, for example by means of an infrared radiator or other suitable heat source. The heat is transmitted through the membrane to the nonwoven fabric 13 transferred to the fibers 11 by at least partial melting or softening of the fibers 11 to consolidate. The supply of heat can be the connection between individual fibers 11 strengthen and help to keep the nonwoven fabric in a compacted state. An example of a suitable material for the membrane is silicone.

According to the method of the invention, a first plurality of fibers 11 on the substrate 12 as explained above. Then a component (not in the 1 shown) on the first plurality of fibers 11 on the substrate 12 is transferred, placed. Subsequently, a second plurality of fibers 11 at least a portion of the component and at least a portion of the first plurality of fibers 11 transfer. The transmission of fibers 11 can be interrupted while the component on the first plurality of fibers 11 is placed, and after the component has been placed, the transmission of fibers 11 to be continued. Alternatively, the transfer of fibers 11 not interrupted and the component is placed while fibers 11 on the substrate 12 , the first variety of fibers and / or the component is transferred. For example, the component may be a reinforcement having the function of locally reducing the elongation of the nonwoven fabric, as with reference to FIGS 2A and 2 B is shown in more detail. It may also be a padding, cushioning, electronic component, membrane (eg a waterproof membrane), etc.

The component can be placed manually or by means of a robot arm (not in the 1 shown). In either case, the component may be taken from a stack having a plurality of similar components.

The number of components placed on the first plurality of fibers is arbitrary and may be at least one. It is thus also possible to place two, three or more components on the first plurality of fibers and then fibers 11 to one or more of these placed components. The components may partially or completely overlap or be separated from each other. In accordance with the invention, it is also possible to have one or more first components on the first plurality of fibers 11 to place a second variety of fibers 11 on the first variety of fibers 11 and transferring the one or more first components comprising one or more second components on the second plurality of fibers 11 and / or the one or more first components and a third plurality of fibers 11 on the first variety of fibers 11 and / or the second plurality of fibers 11 and / or the first one or more components and / or the second one or more components. It is thus possible components at different heights in the thickness of the nonwoven fabric 13 embed or insert.

The nonwoven fabric 13 may also undergo certain post-processing or refining steps. For example, heat and / or pressure may be applied to alter the properties of the nonwoven fabric. To do this, different techniques can be used, including passing the nonwoven fabric through two cylinders of a calender. The application of pressure and heat in particular has the effect that the material is densified locally, whereby at least the thickness and / or the extensibility is changed. In addition, transparency can be achieved by this method to achieve visually attractive designs.

It can be a spray on the nonwoven fabric 13 be applied. For example, it is possible to apply a polyurethane (PU) spray which has the properties of the nonwoven fabric 13 would modify locally. The spray may alternatively or in combination have a particular color to the visual aspect of the nonwoven fabric 13 to increase. In particular, the spray can impregnate the nonwoven fabric in such a way that its properties are changed, in particular its mechanical properties; the 2A and 2 B show an exemplary nonwoven fabric 13 , In the examples of 2A and 2 B The nonwoven fabric has the shape of a shoe upper. In the 2A is the part of the nonwoven fabric 13 shown in a planar, two-dimensional configuration, wherein in the 2 B shown in a three-dimensional configuration. The nonwoven fabric 13 has a first variety 21 of fibers that have been transferred to a planar substrate (not in the 2A and 2 B shown) with reference to the above 1 described. Two components 22A and 22B be on the first variety 21 of fibers, and the second plurality of fibers was placed on the first plurality 21 of fibers and the components 22A and 22B transferred as described above. The two components 22A and 22B are still visible through the second plurality of fibers.

In the examples of 2A and 2 B are the components 22A and 22B Reinforcements of the shoe upper, which are located on the medial and the lateral side of the shoe upper. The components in the example of 2A and 2 B consist of TPU. For example, a compact TPU material can be used which ensures good bonding with the TPU fibers and has better recycling properties.

In the examples of 2A and 2 B have the components 22A and 22B one opening each 23A respectively. 23B on. If the second plurality of fibers 11 on the nonwoven fabric 23 is transferred, become the fibers 11 in the openings 23A and 23B arranged. The fibers of the first variety 21 of fibers and the second plurality of fibers are in the openings 23A and 23B connected together, but also outside the components 22A respectively. 22B , That way, the components become 22A respectively. 22B held firmly in place by the fibers. It should be noted that the component in the context of the present invention may have any number of openings or no openings.

Additionally or alternatively, the components may 22A and 22B have at least one extension (not shown in the figures) adapted to engage with fibers 11 to be enclosed. Such an extension could be in the form of an anchor or simply a linear extension. The extension ensures that the component is fixed in the nonwoven and also prevents it unintentional slippage of the component. In general, the component that is on the first variety 21 of fibers, have a shape such that they are held in position by fibers. For this purpose, the component may have a textured surface (not shown in the figures). In this way, the fibers that come in contact with the surface of the component adhere better to the component.

In the example of 2A and 2 B extend the components 23A and 23B to the edges of the shoe upper. In the side view, the edge of the finished nonwoven fabric 13 show that the components 23A and 23B between the first variety 21 of fibers and the second plurality of fibers are included. However, it is also possible that the components 23A and 23B smaller than the shape of the shoe upper and thus completely in the nonwoven fabric 13 are embedded. In this case, it may be that the components 23A and 23B not visible at all, not even at the edge of the nonwoven fabric 13 , depending on the fleece material, color and thickness.

It is also possible that the at least one surface of the component has a fusible layer. The fusible layer may be the first variety 21 of fibers or the second plurality of fibers. Thus, if, for example, a melt-blowing process as described above for the transfer of the fibers to the substrate 12 When used, the hot fibers may melt or soften the fusible layer and bond to the fusible layer. Alternatively, the component may comprise an adhesive that does not apply heat to the fibers 11 liable. Adhesives or fusible layers may be applied to both sides of a component such that the component adheres to both the first plurality of fibers and the second plurality of fibers.

The nonwoven fabric 13 in the 2A and 2 B is shown, was subjected to a heat and pressure treatment in the heel area, whereby the nonwoven layer 21 has become more translucent.

The 3A and 3B show an exemplary nonwoven fabric in the form of a sock-like shoe upper 31 prepared by the method of the invention as described above. How best in the 3B can be seen, the shoe upper 31 a bottom 32 on, which faces a sole of a shoe (not in the 3A and 3B shown). The shoe top 31 thus has a closed geometry except for the foot opening 33 and is essentially sock-like.

A sole structure can be right on the bottom 32 of the shoe upper 31 be applied, for example by sewing, gluing or welding. It is also possible to apply the shoe sole structure by injection molding. If the sole structure has fibers, for example as cushioning or cushioning, it is even possible to remove the fibers from a fiber transfer device 14 as described above, while the shoe upper 31 still on a ledge. Thus, a part of the sole structure (or even the entire sole structure) may be integral with the shoe upper 31 be formed in a single operation.

It is possible that other components on the shoe upper 31 can be attached. It may, for example, a logo or a coating on the shoe upper 31 be applied. It is also possible that a first and a second nonwoven fabric for a shoe upper be prepared as described in this document. Both nonwovens are different parts of the shoe upper. The first nonwoven fabric may be, for example, a back portion that includes a heel counter as a component embedded in the nonwoven fabric, wherein the second nonwoven fabric may be a corresponding front portion that includes a toe cap as a component embedded in the nonwoven fabric. Both parts can then be joined by gluing, sewing, welding, etc. to make the shoe upper. In general, any number of such components can be joined to make a shoe upper.

While the 2A . 2 B . 3A and 3B a nonwoven fabric 13 It should be noted that according to the invention, the nonwoven fabric may generally be used for any articles and products including, for example, whole garments or parts thereof, shoes or parts thereof (including sole structures ), Sports equipment or parts thereof (including bladders and carcasses), bags or parts thereof, accessories and parts thereof, etc. This list is neither exhaustive nor restrictive.

The 5A and 5B show an embodiment of a modification of the idea of the present invention, namely a shoe 51 , the one shoe top 52 and a sole structure 53 having.

The shoe upper was made in a 2D meltblown process. The fibers are blown onto a flat surface to form a base layer. The base layer is then cut, for example, in the shape of a shoe upper and sewn to a Zwickleisten to to create a three-dimensional shape. The Stripes 54 can be produced by applying a thicker layer of fibers, for example by spraying / blowing more fibers into certain areas. The strips can be produced by heat pressing the base layer in the areas where the strips are to be placed. The heat pressing can be done in the areas of the base layer which have a higher thickness. It is also possible that the strips are made separately and then joined to the base layer, eg by thermal pressing. In other embodiments, the strips may be placed on the base layer, and the intermediate structure having at least one strip may then be heat-pressed with the base layer to be bonded together. In thermal pressing, a texture can be created on the strip and / or the base layer. The different strips may have different extensibility, eg 5%, 10% or 15% of the extensibility of the base layer of nonwoven. The strips may advantageously consist of the same material as the base layer. An advantage of this 2D blown fiber / nonwoven technology is that no top layer of TPU is required because the nonwoven is waterproof. In addition, by using the nonwoven fabric, an isotropic top (ie, everywhere with equal elongation) can be made, and then the local elongation can be altered by applying one or more streaks. A strip may wrap around the shoe top or be broken in the form of a patch.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 2006/0276095 A1 [0003]
• WO 2016/099687 A1 [0004]
• WO 2014/167420 A2 [0005]
• GB 1363675 [0006]
• EP 2412856 B1 [0007]

Claims (39)

Method for producing a nonwoven fabric (13), comprising the following steps: a. Providing a substrate (12), the substrate (12) being air-permeable in at least part of its surface; b. Providing a fiber transfer device (14) adapted to transfer fibers (11) to the substrate (12); c. Transferring a first plurality (21) of fibers (11) to the substrate (12); and d. Applying a pressure differential to the air permeable portion of the substrate, wherein the magnitude of the pressure differential across the surface of the substrate (12) is varied. The method of the preceding claim, wherein the air-permeable member has a plurality of holes (114). Method according to one of the preceding claims, wherein the substrate (12) is a three-dimensional shape. Method according to one of the preceding claims, further comprising the steps of: Placing a component (22A, 22B) at least partially on the first plurality (21) of fibers (11) transferred to the substrate (12); and Transferring a second plurality of fibers (11) to at least a portion of the component (22A, 22B) and to at least a portion of the first plurality (21) of fibers (11). A method according to the preceding claim, wherein the component has a three-dimensional shape. A method according to any one of the preceding claims, wherein the fiber transfer device (14) is a meltblown head. Method according to one of Claims 4 to 6 wherein the surface area of the component (22A, 22B) is smaller than the surface area of the nonwoven fabric (13) and the component (22A, 22B) is placed so as to be embedded in the nonwoven fabric (13). Method according to one of Claims 4 to 7 wherein the component (22A, 22B) has at least one extension adapted to be enclosed by fibers (11). Method according to one of Claims 4 to 8th wherein the component (22A, 22B) has at least one opening (23A, 23B) such that fibers (11) of the second plurality of fibers deposited in the opening (23A, 23B) are applied to the first plurality (21) of FIG Fibers (11) are transmitted. Method according to one of Claims 4 to 9 wherein the component (22A, 22B) has a shape such that it is held in position by fibers (11). Method according to one of Claims 4 to 10 wherein the component (22A, 22B) has a textured surface. Method according to one of Claims 4 to 11 wherein at least one surface of the component (22A, 22B) comprises a fusible layer. Method according to one of Claims 4 to 12 wherein the melting temperature of the fusible layer is below the temperature of the fibers (11) as they impinge on the component (22A, 22B). A method according to the preceding claim, wherein the nonwoven fabric is a part of a garment, shoe or sports equipment. Method according to one of Claims 2 to 11 wherein the three-dimensional shape (12) is a last for a shoe or a part thereof. Method according to one of Claims 3 to 15 wherein the three-dimensional shape (12) is spherical and the nonwoven fabric (13) is suitable to be used as a layer of a ball or as a part thereof. The method of any one of the preceding claims, further comprising the step of filling the fiber transfer device (14) with a thermoplastic polyurethane, TPU. Method according to one of Claims 6 to 17 wherein the meltblowing head (14) has a plurality of nozzles (17). A method according to the preceding claim, further comprising the steps of: filling at least a first nozzle (17) with a first material; and filling at least one second nozzle (17) with a second material, wherein the first material and the second material are different. The method of any one of the preceding claims, further comprising the steps of: transmitting the first material for a first period of time; and transferring a second material for a second period of time, wherein the first material and the second material are different. Method according to one of the preceding claims, further comprising the steps of: Transferring a first material to a first part of the substrate (12); and Transferring a second material to a second portion of the substrate (12), wherein the first material and the second material are different. Method according to one of Claims 18 to 21 method further comprising the step of: filling at least one nozzle (17) with a first material and a second material in a side-by-side configuration. Method according to one of the preceding claims, further comprising the following step: Transferring at least a third plurality of fibers (11) onto the substrate (12) after the first plurality (21) of fibers (11) or after the second plurality of fibers (11), wherein the material of the third plurality of fibers is of the Material of the first plurality of fibers and / or the second plurality of fibers is different. Method according to one of the preceding claims, further comprising the following step: Moving the fiber transfer device (14) relative to the substrate (12). The method of any one of the preceding claims, further comprising the step of placing a higher proportion of fibers in a predetermined direction than in other directions. A method according to the preceding claim, further comprising the step of: Controlling the spacing (112) between the fiber transfer device (14) and the substrate (12) and / or controlling the rate of relative movement between the fiber transfer device (14) and the substrate (12). A method according to the preceding claim, wherein the spacing (112) and / or speed is varied during transfer of the fibers (11) to the substrate (12). Method according to one of Claims 3 to 27 wherein the three-dimensional shape (12) is concave and the method further comprises the step of: transferring the fibers (11) to an inner surface of the three-dimensional shape (12). Method according to one of the preceding claims, further comprising the steps of: Coating the substrate (12) at least partially with a base layer; and Transferring at least a portion of the first plurality (21) of fibers (11) and / or the second plurality of fibers (11) to the base layer. A method according to the preceding claim, wherein the base layer is a woven fabric, a nonwoven fabric or a knit fabric. Method according to one of the preceding claims, further comprising the following step: Transferring the first plurality (21) of fibers (11) and / or the second plurality of fibers (11) to a first region of the substrate (12) but not to a second region. Method according to one of the preceding claims, wherein the substrate (12) is textured. Method according to one of the preceding claims, further comprising the following step: Placing a removable membrane over the nonwoven fabric (13) while on the substrate (12). A method according to the preceding claim, wherein the membrane is textured. Method according to one of the preceding claims, further comprising the following step: Applying heat to the nonwoven fabric (13) while it is on the substrate (12). A nonwoven fabric (13) produced according to a method according to any one of the preceding claims. A method of manufacturing a shoe upper (13, 31) comprising the steps of: producing a first nonwoven fabric (13) according to the method of Claim 14 wherein the first nonwoven fabric is a part of the shoe upper (13, 31). A method of manufacturing a shoe upper (13, 31) according to the preceding claim, further comprising the steps of: producing a second nonwoven fabric according to the method of Claim 14 wherein the second nonwoven fabric is a part of the shoe upper (13, 31); and bonding the first nonwoven fabric (13) and the second nonwoven fabric. Shoe upper (13, 31), which according to a method according to one of Claims 37 or 38 will be produced.

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